EP1845117A1 - Polymerisationsverfahren - Google Patents

Polymerisationsverfahren Download PDF

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Publication number
EP1845117A1
EP1845117A1 EP06112472A EP06112472A EP1845117A1 EP 1845117 A1 EP1845117 A1 EP 1845117A1 EP 06112472 A EP06112472 A EP 06112472A EP 06112472 A EP06112472 A EP 06112472A EP 1845117 A1 EP1845117 A1 EP 1845117A1
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EP
European Patent Office
Prior art keywords
polymer
stirrer
fluoropolymer
advantageously
per
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06112472A
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English (en)
French (fr)
Inventor
Vincenzo Arcella
Valeri Kapeliouchco
Stefano Ferrero
Aniello Gargiulo
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Solvay Specialty Polymers Italy SpA
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Solvay Solexis SpA
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Publication date
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Priority to EP06112472A priority Critical patent/EP1845117A1/de
Priority to CN2007800199672A priority patent/CN101454358B/zh
Priority to US12/296,216 priority patent/US7915356B2/en
Priority to DE602007007922T priority patent/DE602007007922D1/de
Priority to JP2009504705A priority patent/JP5371739B2/ja
Priority to AT07727886T priority patent/ATE474861T1/de
Priority to EP07727886A priority patent/EP2007822B1/de
Priority to PCT/EP2007/053418 priority patent/WO2007116031A1/en
Publication of EP1845117A1 publication Critical patent/EP1845117A1/de
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/01—Processes of polymerisation characterised by special features of the polymerisation apparatus used
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/23—Mixers with rotary stirring devices in fixed receptacles; Kneaders characterised by the orientation or disposition of the rotor axis
    • B01F27/232—Mixers with rotary stirring devices in fixed receptacles; Kneaders characterised by the orientation or disposition of the rotor axis with two or more rotation axes
    • B01F27/2322—Mixers with rotary stirring devices in fixed receptacles; Kneaders characterised by the orientation or disposition of the rotor axis with two or more rotation axes with parallel axes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/84—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis with two or more stirrers rotating at different speeds or in opposite directions about the same axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/85—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis with two or more stirrers on separate shafts
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
    • C08F14/18—Monomers containing fluorine
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
    • C08F14/18—Monomers containing fluorine
    • C08F14/26—Tetrafluoroethene
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
    • Y10S526/918—Polymerization reactors for addition polymer preparation

Definitions

  • the invention pertains to a process for polymerising fluorinated monomer, to a fluoropolymer, and to a moulding process for moulding fluoropolymer.
  • Suitable mixing devices are generally comprised in the polymerisation devices enabling notably:
  • reaction takes place between a reactant (i.e. the gaseous fluorinated monomer) in gas phase and the active sites in solid phase (i.e. the growing polymer chain), and that the liquid typically plays, inter alia, the role of withdrawing the enthalpy of the reaction.
  • a reactant i.e. the gaseous fluorinated monomer
  • active sites in solid phase i.e. the growing polymer chain
  • US 3245972 B (DUPONT DE NEMOURS) 12.04.1966 discloses a process for obtaining a polytetrafluoroethylene (PTFE) molding powder, said process comprising polymerizing tetrafluoroethylene (TFE) in aqueous medium using stirring equipment with power consumption in the range 0.0004 to 0.002 kg m/sec/ml and with a ratio of power to discharge coefficient of at least 1.4.
  • PTFE polytetrafluoroethylene
  • impellers such as, notably, a vertically disposed flat paddle, a stirrer with flat blades pitched at an angle of 15 degrees to the horizontal, a marine propeller and a bladed propeller having horizontal shear tips; a flat blade paddle stirrer arranged vertically with ratio of power to discharge coefficient of 3.4 is preferred.
  • US 3462401 B (DAIKIN KOGYO CO., LTD) 19.08.1969 disclose a process for the preparation of nearly spherical granular PTFE molding powder, said process comprising polymerizing in presence of a water insoluble organic liquid under vigorous stirring.
  • the reaction device is a polymerisation vessel equipped with either an anchor type agitator or a four-vaned propeller in its bottom.
  • US 5760148 B (DYNEON GMBH) 02.06.1998 discloses the suspension polymerisation of TFE for obtaining uniform, compact and spherical grains of PTFE in a reactor equipped with a stirrer element generating both an axial flow component and a tangential flow component, with formation of a vortex in vicinity of the stirrer element, optionally by means of rotatable baffles without producing dead water zones.
  • baffles have several drawbacks, notably:
  • US 2209287 B (SIMPSON W.L.) 23.07.1940 discloses a mixing device comprising a tank and a mixer having two coaxially mounted propellers of different sizes and means for driving said propellers in opposite directions.
  • US 3330818 B (MONSANTO CO.) 11.07.1967 relates to an improved process for the low pressure polymerization of olefins, especially ethylene, wherein a mixing system comprising two impellers mounted on coaxial separate shafts (one from the top, one from the bottom) rotating in opposite directions is used for forming a high turbulence zone, yielding a significant reduction in plating.
  • GB 2158727 (CHEM-PLANT STAINLESS LIMITED) 20.11.1985 discloses a generally cylindrical mixer vessel comprising a central shaft extending vertically and carrying an agitator rotatable about the axis of said shaft in one direction and stirrer blades rotatable about the axis of the shaft in the opposite direction.
  • US 6252018 B (BASF AG) 26.06.2001 relates to a stirring system device particularly suitable for the emulsion polymerisation of ethylenically unsaturated monomers, said stirring system comprising multistage, very close-clearance stirring elements, which produce not only a tangential flow component but also an axial flow field.
  • polymer particles morphology and shape factors as well as comonomer distribution are strongly influenced by the mixing flow; particle size distribution and particle shape is notably affected by the mixing energy distribution, by the shear force, by the presence of dead zones, etc.
  • US 6262209 (AUSIMONT S.P.A.) 17.07.2001 discloses a process for producing modified PTFE by suspension polymerization, said process allowing obtaining at high productivity a product having improved processing features.
  • Said polymerization process comprises polymerizing a mixture of TFE and a perfluoroalkyl vinyl ether and/or a perfluorodioxole comonomer at a pressure from 15 to 30 bar with a perfluorinated surfactant in the presence of a buffering salt, and a persulfate and a reducing agent as initiator.
  • a first object of the invention is a polymerisation process for the manufacture of a fluoropolymer [polymer (F)], said process comprising polymerising at least one fluorinated monomer in a polymerization medium, wherein said polymerization medium is mixed by means of a stirring system comprising at least two counter-rotating impellers.
  • the polymerization process advantageously occurs with improved homogeneity, without composition, pressure or temperature gradients, thus advantageously enabling obtaining homogeneous polymer composition with no risk of local overheating.
  • polymer (F) obtained from the process of the invention possesses advantageously improved morphology (percentage of organized structures, i.e. of particles of regular shape) and, hence, advantageously good free flowing properties which make it suitable for being processed by compression moulding (e.g. automatic moulding; RAM extrusion) with no need of intermediate milling or grinding process or other size reduction process nor of granulation or spheroidization process.
  • compression moulding e.g. automatic moulding; RAM extrusion
  • an object of the invention is a fluoropolymer [polymer (F)] under the form of particles having a sphericity shape factor (L max /L min ) of 1.5/1 or less and an angle of repose of 40° or less.
  • Another object of the invention is a moulding process for the manufacture of a moulded article, said process comprising:
  • the moulding process of the invention is particularly advantageous, as moulded good are advantageously produced with substantial energy savings, as there is no need of size reduction process which are highly energy demanding.
  • polymerizing the fluorinated monomer in the polymerization medium provides a heterogeneous reaction mixture com prising the polymer (F) product in the polymerization medium.
  • the polymerization medium of the process of the invention advantageously comprises water.
  • the polymerization medium of the invention consists essentially of water, in which are generally either solubilized or dispersed the required polymerization ingredients (like notably one or more monomers, initiators, surfactants, etc.)
  • heterogeneous reaction mixture refers to a reaction mixture having at least two phases.
  • One phase is termed the “continuous phase”, which comprises a fluid, preferably water, and the other is termed the “solid phase”, comprising the polymer (F) product.
  • heterogeneous reaction mixture is intended to encompass the product of both dispersion polymerizations, in which the polymerization starts out homogeneous, and emulsion polymerizations, in which the polymerization starts out heterogeneous and the polymerization initiator is preferentially solubilized in the continuous phase.
  • a compound is "preferentially solubilized” in one phase over another when it is more soluble in that phase.
  • the polymerization medium of the present invention can be initially homogeneous, i.e. it is a medium wherein the fluorinated monomer(s), and all other optional polymerization ingredients (such as notably the initiator) are solubilized, and generally becomes heterogeneous as the polymerization proceeds and the polymer is formed.
  • the newly produced polymer (F) advantageously forms the solid phase of the reaction.
  • the polymer can be notably stabilized as a dispersion of the solid phase by the presence of a suitable surfactant which reduces the surface tension between the phases.
  • This type of polymerization processes is generally known as dispersion polymerization.
  • a general description of dispersion polymerization can be found in BARRET, K.E.J.Dispersion Polymerization in Organic Media. London: Wiley, 1975 . ; and in NAPPER, D.H.Polymer Stabilization of Colloidal Dispersion. London: Academic Press, 1983 ..
  • the polymerization medium advantageously comprises a surfactant.
  • the surfactant is preferably a fluorinated surfactant.
  • R f ⁇ is a (per)fluoroalkyl chain C 5 -C 16 or a (per)fluoropolyoxyalkylene chain
  • X - is -COO - or -SO 3 -
  • M + is selected from H + , NH 4 +
  • an alkaline metal ion and j can be 1 or 2.
  • fluorinated surfactants mention may be made of ammonium and/or sodium perfluorocarboxylates, and/or (per)fluoropolyoxyalkylenes having one or more carboxylic end groups.
  • the fluorosurfactant is chosen from :
  • a co-stabilizer is advantageously used in combination with the surfactant. Paraffins with a softening point in the range 48°C - 62°C are preferred as co-stabilizers.
  • the polymer (F) can be present in the solid phase as discrete particles which are typically kept in suspension by mixing. This process is generally called suspension polymerization.
  • the term "particle” is intended to denote a mass of material that, from a geometrical point of view, has a definite three-dimensional volume and shape, characterized by three dimensions, wherein none of said dimensions exceed the remaining two other dimensions of more than 20 times.
  • the process of the invention is carried out in suspension.
  • the Applicant thinks, without this limiting the scope of the invention, that the vigorous stirring and the highly homogenous mixing achieved via the use of the stirring system comprising the counter-rotating impellers is particularly advantageous for suspension polymerization.
  • the so-obtained mixing can advantageously promote a precipitation of the polymer (F) under the form of very regular particles having spheroidal shapes.
  • a small amount typically from 1 to 1500 ppm, preferably from 5 to 1000 ppm, more preferably from 10 to 300 ppm of a fluorinated surfactant as above described can be used.
  • a buffering salt at alkaline pH can be used.
  • Suitable buffering salts at alkaline pH are notably alkaline metal pyrophosphates and/or ammonium or alkaline metal oxalates.
  • the process of the invention advantageously comprises polymerizing the fluorinated monomer in the presence of a radical initiator.
  • radical initiators suitable for the process according to the invention are compounds capable of initiating and/or accelerating the polymerization.
  • the initiator is advantageously included in a concentration ranging from 0.001 to 20 percent by weight of the polymerization medium.
  • Organic free radical initiators can be used and include, but are not limited to, the following : acetylcyclohexanesulfonyl peroxide; diacetylperoxydicarbonate; dialkylperoxydicarbonates such as diethylperoxydicarbonate, dicyclohexylperoxydicarbonate, di-2-ethylhexylperoxydicarbonate; tert-butylperneodecanoate; 2,2'-azobis(4-methoxy-2,4dimethylvaleronitrile; tert-butylperpivalate; dioctanoylperoxide; dilauroyl-peroxide; 2,2'-azobis (2,4-dimethylvaleronitrile); tert-butylazo-2-cyanobutane; dibenzoylperoxide; tert-butyl-per-2ethylhexanoate; tert-butylpermale
  • Redox systems comprising at least two components forming a redox couple, such as dimethylaniline-benzoyl peroxide, diethylaniline-benzoyl peroxide and diphenylamine-benzoyl peroxide can also be used to initiate the polymerization.
  • a redox couple such as dimethylaniline-benzoyl peroxide, diethylaniline-benzoyl peroxide and diphenylamine-benzoyl peroxide can also be used to initiate the polymerization.
  • Inorganic free radical initiators can be used and include, but are not limited to, the followings : persulfates, like sodium, potassium or ammonium persulfates, permanganates, like potassium permanganate.
  • a redox polymerization initiator comprising a combination of a persulfate of an alkaline metal or ammonium with a Fe(II) salt as reducing agent (such as the Mohr salt), a halogen acid salt and a sulfite as described in US patent 6,822,060 or a Ce(IV) salt/oxalic acid combination as described in US patent 4,654,406 or a disuccinic acid peroxide (DSAP) and ammonium sulphite (AMS) combination as described in US 4,766,188 , can be notably used.
  • the halogen acid salt as above mentioned is represented by the general formula YXO 3 wherein X is a chlorine atom, a bromine atom or an iodine atom and Y is a hydrogen atom, ammonium, an alkali metal or an alkaline earth metal.
  • the sulfite as above mentioned is represented by general formulae Z' 2 SO 3 wherein Z is ammonium, an alkali metal or Z"SO 3 wherein Z" is an alkaline earth metal.
  • a redox polymerization initiator comprising a persulfate of an alkaline metal or ammonium, preferably potassium or ammonium persulfate with a Fe(II) salt, preferably the Mohr salt (Iron (II) sulphate hexahydrate of formula (NH 4 ) 2 Fe(SO 4 ) 2 ⁇ 6H 2 O) is preferred.
  • both the components may be added simultaneously or sequentially to the reaction vessel. It is preferred that either one is preliminarily charged into the reaction vessel, then the other is intermittently or continuously added during the polymerization.
  • the polymerization may be also carried out in the presence of chain regulators or other polymerization additives, such as suspending agents, anti-fouling agents, and the like.
  • chain regulator When a chain regulator is used, this is employed in the usual amounts. To be more specific, the chain regulators are generally used in an amount of about 0.5 to 5 % by weight with respect to the fluorinated monomer(s) employed. The chain regulator may be employed all at the start of the polymerization or else in portions or continuously during polymerization.
  • polymer encompasses oligomers and polymers, having molecular weight from 10 2 to 10 8 ; also the term encompasses homopolymers and copolymers, depending upon the number of monomers which are employed.
  • fluoropolymer and “polymer (F)” are intended to denote any polymer comprising recurring units (R), more than 25 % wt of said recurring units (R) being derived from at least one ethylenically unsaturated monomer comprising at least one fluorine atom (hereinafter, fluorinated monomer).
  • the fluoropolymer comprises preferably more than 30 % wt, more preferably more than 40 % wt of recurring units derived from the fluorinated monomer.
  • the fluorinated monomer can further comprise one or more other halogen atoms (Cl, Br, I). Shall the fluorinated monomer be free of hydrogen atom, it is designated as per(halo)fluoromonomer. Shall the fluorinated monomer comprise at least one hydrogen atom, it is designated as hydrogen-containing fluorinated monomer.
  • Non limitative examples of fluorinated monomers are notably tetrafluoroethylene (TFE), vinylidene fluoride (VdF), chlorotrifluoroethylene (CTFE), and mixtures thereof.
  • the fluoropolymer may comprise recurring units derived one first monomer, said monomer being a fluorinated monomer as above described, and at least one other monomer [comonomer (CM), hereinafter].
  • CM comonomer
  • CM comonomer
  • HCM hydrogenated (i.e. free of fluorine atom)
  • FCM fluorinated (i.e. containing at least one fluorine atom)
  • HCM hydrogenated comonomers
  • ethylene propylene
  • vinyl monomers such as vinyl acetate
  • acrylic monomers like methyl methacrylate
  • acrylic acid methacrylic acid and hydroxyethyl acrylate
  • styrene monomers like styrene and p-methylstyrene.
  • FCM fluorinated comonomers
  • each of R f3 , R f4 , R f5 , R f6 is independently a fluorine atom, a C 1 -C 6 fluoro- or per(halo)fluoroalkyl, optionally comprising one or more oxygen atom, e.g. -CF 3 , -C 2 F 5 , -C 3 F 7 , -OCF 3 , -OCF 2 CF 2 OCF 3 .
  • the polymer (F) is a hydrogen-containing fluoropolymer.
  • hydrogen-containing fluoropolymer it is meant a fluoropolymer as above defined comprising recurring units derived from at least one hydrogen-containing monomer. Said hydrogen-containing monomer may be the same monomer as the fluorinated monomer or can be a different monomer.
  • this definition encompasses notably copolymers of one or more per(halo)fluoromonomer (for instance tetrafluoroethylene, chlorotrifluoroethylene, hexafluoropropylene, perfluoroalkylvinylethers, etc.) with one or more hydrogenated comonomer(s) (for instance ethylene, propylene, vinylethers, acrylic monomers, etc.), and/or homopolymers of hydrogen-containing fluorinated monomers (for instance vinylidene fluoride, trifluoroethylene, vinyl fluoride, etc.) and their copolymers with fluorinated and/or hydrogenated comonomers.
  • per(halo)fluoromonomer for instance tetrafluoroethylene, chlorotrifluoroethylene, hexafluoropropylene, perfluoroalkylvinylethers, etc.
  • hydrogenated comonomer(s) for instance ethylene, propylene, vinylethers
  • the hydrogen-containing fluoropolymer are preferably chosen among : (F-1) TFE and/or CTFE copolymers with ethylene, propylene or isobutylene (preferably ethylene), with a molar ratio per(halo)fluoromonomer(s)/hydrogenated comonomer(s) of from 30:70 to 70:30, optionally containing one or more comonomers in amounts of from 0.1 to 30 % by moles, based on the total amount of TFE and/or CTFE and hydrogenated comonomer(s) (see for instance U.S. Pat. No. 3,624,250 and U.S. Pat. No.
  • (F-2) Vinylidene fluoride (VdF) polymers optionally comprising reduced amounts, generally comprised between 0.1 and 15 % by moles, of one or more fluorinated comonomer(s) (see for instance U.S. Pat. No. 4,524,194 and U.S. Pat. No. 4,739,024 ), and optionally further comprising one or more hydrogenated comonomer(s); and mixtures thereof.
  • the polymer (F) is a per(halo)fluoropolymer.
  • per(halo)fluoropolymer is intended to denote a fluoropolymer substantially free of hydrogen atoms.
  • per(halo)fluoropolymer consists essentially of recurring units derived from ethylenically unsaturated monomers comprising at least one fluorine atom and free of hydrogen atoms [per(halo)fluoromonomer) (PFM)].
  • the per(halo)fluoropolymer can comprise recurring units comprising one or more other halogen atoms (Cl, Br, I).
  • the per(halo)fluoropolymer can be a homopolymer of a per(halo)fluoromonomer (PFM) or a copolymer comprising recurring units derived from more than one per(halo)fluoromonomer (PFM).
  • PFM per(halo)fluoromonomer
  • PFM per(halo)fluoromonomer
  • PFM per(halo)fluoromonomers
  • the per(halo)fluoropolymer is advantageously chosen among homopolymers of tetrafluoroethylene (TFE) or copolymers of TFE with at least one per(halo)fluoromonomer (PFM).
  • TFE tetrafluoroethylene
  • PFM per(halo)fluoromonomer
  • Preferred per(halo)fluoropolymer is selected among TFE homo- and copolymers comprising recurring units derived from at least one per(halo)fluoromonomer (PFM) chosen among the group consisting of :
  • More preferred per(halo)fluoropolymers are selected among TFE homo- and copolymers comprising recurring units derived from at least one fluorinated comonomer chosen among the group consisting of:
  • the per(halo)fluoromonomer (PFM) is present in the TFE copolymer in an amount of advantageously at least 0.01, preferably 0.1 % by moles, with respect to the total moles of TFE and per(halo)fluoromonomer (PFM).
  • the per(halo)fluoromonomer (PFM) is present in the TFE copolymer in an amount of advantageously at most 3 % by moles, preferably 1 % by moles, with respect to the total moles of TFE and per(halo)fluoromonomer (PFM).
  • TFE homo- and copolymers wherein the fluorinated comonomer is perfluoromethylvinylether, a mixture of perfluoromethylvinylether and perfluoropropylvinylether, a mixture of perfluoroethylvinylether and perfluoropropylvinylether, or perfluoropropylvinylether.
  • the polymer (F) is a TFE copolymer as above described.
  • TFE homo- and copolymers which can be produced by the process of the invention are commercially available from Solvay Solexis S.p.A. under the trade name of ALGOFLON ® PTFE.
  • the polymer (F) is advantageously non melt-processable.
  • non melt-processable is meant that the polymer (F) cannot be processed (i.e. fabricated into shaped articles such as films, fibres, tubes, wire coatings and the like) by conventional melt extruding, injecting or casting means. This generally requires that the melt viscosity at the processing temperature be more than 10 7 poise, preferably in the range from 10 7 to 10 13 poise, and most preferably from 10 7 to 10 12 poise.
  • the melt viscosity of the polymer (F) can be measured according to the method described in AJROLDI, G., et al. Some Rheological Properties of molten Polytetrafluoroethylene. J. appl. polym. sci.. 1970, vo1.14, p.79-88 . by tensile creep test at 360°C; this method is particularly suitable for high viscosity compounds (melt viscosity exceeding 10 10 ).
  • melt viscosity of the polymer (F) can be measured according to ASTM D-1238-52T, using a cylinder, orifice and piston tip made of a corrosion-resistant alloy, charging a 5.0 g sample to the 9.5 mm inside diameter cylinder which is maintained at a temperature exceeding melting point, extruding the sample 5 minutes after charging through a 2.10 mm diameter, 8.00 mm long square-edged orifice under a load (piston plus weight) of 5 kg. Melt viscosity is calculated in poise from the observable extrusion rate in grams per minute.
  • stirrers or impellers can be used in the mixing system of the process of the invention.
  • Impellers can be roughly divided into three broad classes as a function of the mixing flow they generate: axial-flow impellers, radial-flow impellers and mixed-flow impellers.
  • stirrer types are arranged in Figure 1 according to the predominant flow pattern they produce, impellers (A) to (F) predominantly yielding a radial (or tangential) flow, and impellers (G) to (N) predominantly yielding an axial (or vertical) flow.
  • Radial-flow impellers have blades which are generally parallel to the axis of the drive shaft.
  • Non limitative examples of radial-flow impellers are notably:
  • Axial-flow and mixed flow impellers include all impeller in which the blade(s) make(s) an angle of less than 90° with the plane of rotation.
  • Non limitative examples of said impellers are notably:
  • Each of the impellers of the stirring system of the process of the invention is advantageously independently chosen among the group consisting of a turbine stirrer, an impeller stirrer, a grid impeller, a cross-beam impeller, a blade impeller, a low-speed anchor stirrer, a rotor-stator stirrer, a toothed disk, a paddle stirrer with pitched blades, a propeller stirrer, a multistage stirrer with pitched stirring surfaces, a low-speed helical ribbon stirrer and a hollow stirrer.
  • the stirring system comprise at least one paddle stirrer with pitched blades.
  • the stirring system comprises at least one impeller comprising at least one blade making an angle of advantageously less than 60°, preferably less than 50° and advantageously at least 20°, preferably at least 30°, most preferably at least 40° with the plane of rotation.
  • the stirring system used for mixing in the process of the invention comprises at least two counter-rotating impellers.
  • two counter-rotating impellers as used herein is intended to denote two impellers who rotate in the opposite direction, that is to say that one of them rotates clockwise and the other rotates counter-clockwise.
  • the stirring system may comprise two impellers or more than two (i.e. three, four or more impellers); should the stirring system comprise more that two impellers, it is essentially that at least one of them rotates in the opposite direction than the others.
  • Figure 7 depicts an example of a stirring system comprising three impellers;
  • (A) is a side-elevation view of the reaction vessel (70), while
  • (B) is a section view of the same.
  • reaction vessel (70) comprising walls (71) and bottom (72) so as to define a cylindrical shape having round bottom, is equipped with three paddle stirrers with pitched blades (73, 74, 75) mounted on three parallel rotation shafts (76, 77, 78); each of the impellers comprises four pitched blades (79) forming a 45° angle with the plane of the rotation.
  • One of the impellers (73, 74, 75) rotates in an opposite direction with respect to the two others. For instance, impellers 74 and 75 rotate clockwise, while impeller 73 rotates counter-clockwise.
  • the stirring system comprises two counter-rotating impellers.
  • the impellers of the mixing system of the process of the invention can be of the same type or can be of different types.
  • a paddle stirrer with pitched blades e.g. rotating clockwise can be used in combination with another paddle stirrer with pitched blades e.g. rotating counter-clockwise.
  • a paddle stirrer with pitched blades e.g. rotating clockwise can be used in combination with a propeller stirrer or a marine-type propeller stirrer e.g. rotating counter-clockwise.
  • all the impellers are of the same type.
  • the stirring system comprises two paddle stirrers with pitched blades; even more preferably, said paddle stirrers have pitched blades forming an angle of about 45° with the plane of rotation.
  • the impellers of the stirring system can have the same diameter or may have different diameter. In general, the impellers will have the same diameter. This layout will be particularly preferred when the impellers are of the same type.
  • Figure 8 depicts an example of a stirring system comprising impellers rotating around distinct parallel rotational axes;
  • (A) is a side-elevation view of the reaction vessel (80), while
  • (B) is a section view of the same.
  • reaction vessel (80) comprising walls (81) and bottom (82) so as to define a cylindrical shape having round bottom, is equipped with two paddle stirrer with pitched blades (83, 84) mounted on two parall el rotation shafts (85, 86); each of the impellers comprises four pitched blades (87) forming a 45° angle with the plane of the rotation.
  • the reaction vessel is generally equipped with means for feeding monomer(s), initiators, liquid medium and other polymerization ingredients (not shown) and means for withdrawing the polymer suspension, generally from the vessel bottom (82) (not shown).
  • impellers rotate around the same rotational axis, that is to say preferably they are coaxial.
  • the impellers (54, 55) are mounted on separate coaxial shafts (52 and 56) in the reaction vessel (50); the impellers may be mounted as shown in Figure 5 or may be mounted on the sides of the reaction vessel opposed to each other, that is to say that the axis of the shaft can be vertical, as depicted in figure 5 or horizontal.
  • Figure 5 depicts an example of the stirring system according to the first embodiment of the invention; (A) is a side-elevation view of the reaction vessel (50), while (B) is a section view of the same.
  • reaction vessel (50) comprising walls (51) and bottom (57) so as to define a cylindrical shape having round bottom, is equipped with two paddle stirrer with pitched blades (54, 55) mounted on two separated coaxial rotation shafts (52, 56), the former (52) from the top of the vessel, the latter (56) from the bottom; each of the impellers comprises four pitched blades (53) forming a 45° angle with the plane of the rotation.
  • the reaction vessel is generally equipped with means for feeding monomer(s), initiators, liquid medium and other polymerization ingredients (not shown) and means for withdrawing the polymer suspension, generally from the vessel bottom (57) (not shown).
  • the impellers are mounted on the same rotation shaft (60) as shown in Figure 6.
  • Figure 6 depicts an example of the stirring system according to the second preferred embodiment of the invention;
  • (A) is a side-elevation view of the reaction vessel (65), while
  • (B) is a section view of the same.
  • reaction vessel (65) comprising walls (63) and bottom (64) so as to define a cylindrical shape having round bottom, is equipped with two paddle stirrer with pitched blades (60) mounted on the same rotation shaft (62); each of the impellers comprises four pitched blades (61) forming a 45° angle with the plane of the rotation.
  • the reaction vessel is generally equipped with means for feeding monomer(s), initiators, liquid medium and other polymerization ingredients (not shown) and means for withdrawing the polymer suspension, generally from the vessel bottom (64) (not shown).
  • the impellers of the stirring system of the process of the invention can rotate at the same rotation speed or at a different rotation speed.
  • each impeller will be set as a function of the impeller type and the impeller and reaction vessel diameter according to good practices well-known to the skilled in the art.
  • the energy density obtained with the stirring system is of advantageously at least 2 kW/m 3 , preferably at least 2.5 kW/m 3 , more preferably at least 3 kW/m 3 .
  • Maximum energy density is not particularly critical.
  • the energy density obtained with the stirring system is of advantageously at most 15 kW/m 3 , preferably at most 12.5 kW/m 3 , more preferably at most 10 kW/m 3 .
  • the Applicant thinks, without this limiting the scope of his invention, that by means of the double stirring system of the invention it is advantageously possible to obtain, at given average energy density, an optimized distribution of said energy density throughout the entire reaction vessel, thus advantageously avoiding the presence of dead zones, wherein the local energy density is less than 2 kW/m 3 , as generally observed with single stirring devices.
  • the speed of rotation of the impeller can vary in a broad domain; generally, speed of rotation of each of the impeller is of advantageously at least 150 rpm, preferably of at least 175 rpm, more preferably of at least 200 rpm and is of advantageously at most 1500 rpm, preferably of at most 1000 rpm, more preferably of at most 500 rpm.
  • speed of rotation of the impeller is advantageously selected between 250 and 450 rpm.
  • speeds of rotation of the impellers are different and it is preferred that the upper impeller has a higher speed of rotation than the lower impeller(s).
  • speed of rotation of the lower impeller is advantageously selected between 280 and 360 rpm and speed of rotation of the upper impeller is advantageously selected between 300 and 400 rpm.
  • Another object of the invention is a fluoropolymer [polymer (F)] under the form of particles having a sphericity shape factor (L max /L min ) of 1.5/1 or less and an angle of repose of 40° or less.
  • the process of the invention is particularly suitable for obtaining the fluoropolymer [polymer (F)] as above detailed; nevertheless, any other suitable process can be used for obtaining said polymer (F).
  • the sphericity shape factor of polymer (F) is, to the purpose of the invention, intended to denote the ratio (L max /L min ) between the maximum dimension (L max ) of a particle and the minimum dimension (L min ) of the same, measured by image analysis from microscopy.
  • the particles of polymer (F) of the invention have a sphericity shape factor of advantageously 1.4/1 or less, preferably of 1.3/1 or less.
  • the particles of polymer (F) have an angle of repose of advantageously 39° or less, preferably 38° or less.
  • the angle of repose is a measurement of flowability of particulate polymer (F).
  • F particulate polymer
  • ⁇ angle between the edge of the pile and the horizontal surface
  • Material with a low angle of repose forms flatter piles than material with a high angle of repose.
  • the angle of repose can be determined according to ASTM D 6393-99 standard; according to this method, a stainless steel funnel (upper inner diameter: 40 mm, bottom inner diameter: 6 mm, height: 40 mm) with an orifice (inner diameter: 6 mm, length: 3 mm) is set above a horizontal plane (92) at a distance of 20 mm.
  • the polymer (F) to be tested is introduced to the funnel, goes down through the funnel, and accumulates on the floor, yielding a conical pile (91); then the top of the accumulated powder reaches to the outlet of the funnel.
  • the polymer (F) of the invention thanks to the sphericity shape factor and the angle of repose of its particles advantageously possesses adequate processing and flowability properties which make it suitable for processing, e.g. by automatic moulding or RAM extrusion, with no size reduction nor spheroidization (pelletization) pre-treatment.
  • an object of the invention is a moulding process for the manufacture of moulded articles, said process comprising:
  • the fluoropolymer [polymer (F)] used in the moulding process as above detailed is the polymer (F) of the invention.
  • the term size reduction step is intended to encompass all treatments wherein the polymer (F) is submitted to conditions wherein its average particle size is modified and/or the morphology of the powder is modified (e.g. modification of sphericity shape factor and/or of the angle of repose).
  • Non limitative examples of size reduction steps well known to those skilled in the art are milling or grinding processes.
  • the moulding process of the invention can comprise additional step, well-known to the skilled of the art.
  • the moulding process can notably comprise a drying step, wherein the polymer (F) is separated from the polymerization medium, and/or a compounding step wherein the polymer (F) is mixed to additives like notably pigments, fillers, stabilizers.
  • the polymer (F) is preferably non melt-processable, as above described.
  • the moulding process of the invention generally comprises the following steps:
  • TFE homopolymers and copolymer as above described are usually sintered at a temperature of above 340°C, preferably of above 350°C, more preferably of above 360°C.
  • the moulding process of the invention is particularly suitable for moulding TFE homopolymers and copolymers as above described.
  • the moulding process comprises compression moulding the polymer (F) by automatic moulding.
  • a mould is generally filled with polymer (F) from a storage hopper by means of a gravimetric or volumetric metering system.
  • polymer (F) obtained from polymerization step (i) as above described advantageously possesses suitable free flowing properties to be used as such in the automatic moulding process; in particular polymer (F) can be advantageously fed using said gravimetric or volumetric metering systems with no risk of blocking the device, assuring advantageously homogeneous feeding rate.
  • the moulding process comprises compression moulding by RAM extruding.
  • the polymer (F) is fed via a gravimetric or volumetric metering device into a cylindrical die tube and compressed with a ram, which forces the compacted material further along the tube to the sintering zone.
  • polymer (F) obtained from polymerization step (i) as above described advantageously possesses suitable free flowing properties to be used as such in the RAM extrusion process; in particular polymer (F) can be advantageously fed using said gravimetric or volumetric metering systems with no risk of blocking the device, assuring advantageously homogeneous feeding rate.
  • a cylindrical block having 90 mm diameter and a weight of 3 kg was moulded under a pressure of 300 kg/cm 2 and sintered at 370°C with a pre-determined temperature programme.
  • Specimens according to ASTM D638 method were prepared and stretched until break with deformation rate equal to 50 mm/min by a tensile dynamometer.
  • a 1 kg tubular block having 100 mm external diameter and 43 mm internal diameter was moulded under a pressure of 300 kg/cm 2 .
  • the tubular block was sintered at 370°C and successively skived on a lathe in a tape (film) having 125 micron thickness. During the skiving, the tape homogeneity was evaluated by indicating with a visual method the presence of:
  • the dielectric strength according to ASTM D 149 method and the optical characteristics (transmittance and haze) on a spherical Hazemeter according to ASTM D1003 method were determined.
  • the sphericity shape factor was determined by image analysis of microscopic magnifications of polymer (F) particles. Shape factor was determined as an average of five determinations.
  • the angle of repose can be determined according to ASTM D 6393-99 standard; according to this method, a stainless steel funnel (upper inner diameter: 40 mm, bottom inner diameter: 6 mm, height: 40 mm) with an orifice (inner diameter: 6 mm, length: 3 mm) was set above a horizontal plane (92) at a distance of 20 mm.
  • the polymer (F) to be tested was introduced to the funnel, went down through the funnel, and accumulated on the floor, yielding a conical pile (91); then the top of the accumulated powder reached to the outlet of the funnel.
  • the autoclave top was evacuated from ambient air by connecting the autoclave to the vacuum line and subsequently refilling with a nitrogen flow.
  • the initial amount of comonomer (perfluoropropylvinylether (PPVE) see Tables 1) was introduced; the autoclave was then put under stirring at 330 rpm counter-clockwise rotating for the lower impeller and 360 rpm clockwise rotating for the upper impeller, and was pressurized at 17 bar with TFE.
  • the autoclave was brought to the reaction temperature; this temperature was maintained constant for all the duration of the test.
  • the reactor pressure was maintained constant by continuously feeding TFE.
  • the TFE was regulated so as to allow the system to react until the pressure decreases to the desired value, then the autoclave is depressurized.
  • the polymer was discharged in the washer, the mother liquor was removed and the product was washed several times with demineralized water.
  • the polymer successively was separated from the water by a vibrating screen and was dried in an oven at 210°C.
  • the polymerization conditions, the reactants amounts and the results, in terms of particle shape and flowability are reported in Tables 2.
  • a picture of obtained product is reported in Figure 9.
  • the energy density provided by the double stirring system was of 6.3 kW/m 3 .
  • the dried product was found to be suitable for RAM extrusion and for automatic compression moulding.
  • a vertical autoclave having a total volume of 1100 litres equipped with a mixing system comprising two coaxial counter-rotating impellers (paddle stirrers with four pitched blades forming an angle of 45 ° with the plane of rotation, and having a diameter of 380 mm, for a D/d of 2.6)
  • 550 l of demineralized and degassed water were introduced with the amounts specified in Tables 1 of the redox initiator [Ammonium persulphate (APS) and Ammonium Ferrous Sulfate Hexahydrate of formula (NH 4 ) 2 Fe(SO 4 ) 2 ⁇ 6H 2 O), also known as Mohr salt].
  • the autoclave top was evacuated from ambient air by connecting the autoclave to the vacuum line and subsequently refilling with a nitrogen flow.
  • the autoclave was put under stirring at 325 rpm counter-clockwise rotating for the lower impeller and 390 rpm clockwise rotating for the upper impeller, and is pressurized at 17 bar with TFE
  • the reducing agent was introduced in the desired amounts (see the Tables).
  • the autoclave was brought to the reaction temperature; this temperature was maintained constant for all the duration of the test.
  • the reactor pressure was maintained constant by continuously feeding TFE.
  • the TFE feeding was regulated so as to allow the system to react until the pressure decreases to the desired value, then the autoclave is depressurized.
  • the polymer was discharged in the washer, the mother liquor was removed and the product was washed several times with demineralized water. The polymer was successively separated from the water by a vibrating screen and was dried in an oven at 210°C.
  • the dried product was found to be suitable for RAM extrusion and for automatic compression moulding.
  • Example 1 was repeated but using a single standard paddle impeller without baffles, instead of the mixing system comprising two coaxial counter-rotating impellers.
  • the polymerization conditions, the reactants amounts and the results, in terms of particle shape and flowability are reported in Tables 2.
  • the energy density provided by the standard stirring system was of 6.6 kW/m 3 .
  • the dried polymer was milled in an air jets mill so as to obtain a powder having average weight diameter (d 50 ) of about 20 ⁇ m suitable for RAM extrusion.
  • Example 2 was repeated but using a single standard paddle impeller without baffle, instead of the mixing system comprising two coaxial counter-rotating impellers.
  • the energy density provided by the standard stirring system was of 6.6 kW/m 3 .
  • the dried polymer was milled in an air jets mill so as to obtain a powder having average weight diameter (d 50 ) of about 20 ⁇ m suitable for RAM extrusion.
  • A denotes the mixing system comprising two coaxial counter-rotating impellers; B denotes a standard single paddle impeller.
  • (2) APS: ammonium persulfate of formula (NH4) 2 Fe(SO 4 ) 2 H 2 O ; (3) MS: Mohr salt of formula: (NH 4 ) 2 Fe(SO 4 ) 2 ⁇ 6H 2 O; (4) PPVE: perfluoropropylvinylether of formula: CF 2 CF-O-C 3 F 7 .
  • TH transparent halos
  • MAR Marbleizations
  • CR T strength at break in the transverse direction
  • CR L strength at break in the longitudinal direction
  • Ar T elongation at break in the transverse direction
  • Ar L elongation at break in the longitudinal direction
  • PPVE perfluoropropylvinylether content
  • d 50 average particle size
  • DS dielectric strength.

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  • Organic Chemistry (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
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US12/296,216 US7915356B2 (en) 2006-04-11 2007-04-06 Polymerisation process
DE602007007922T DE602007007922D1 (de) 2006-04-11 2007-04-06 Polymerisationsverfahren
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AT07727886T ATE474861T1 (de) 2006-04-11 2007-04-06 Polymerisationsverfahren
EP07727886A EP2007822B1 (de) 2006-04-11 2007-04-06 Polymerisationsverfahren
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US9260543B2 (en) 2009-12-18 2016-02-16 Solvay Specialty Polymers Italy S.P.A. Method for manufacturing fluoroelastomers
CN102770468B (zh) * 2009-12-18 2016-08-10 索尔维特殊聚合物意大利有限公司 用于生产氟弹性体的方法
WO2011073344A1 (en) * 2009-12-18 2011-06-23 Solvay Solexis S.P.A. Method for manufacturing fluoroelastomers
CN102770468A (zh) * 2009-12-18 2012-11-07 索尔维特殊聚合物意大利有限公司 用于生产氟弹性体的方法
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EP2007822A1 (de) 2008-12-31
CN101454358A (zh) 2009-06-10
DE602007007922D1 (de) 2010-09-02
JP5371739B2 (ja) 2013-12-18
JP2009533508A (ja) 2009-09-17
ATE474861T1 (de) 2010-08-15
US20090108501A1 (en) 2009-04-30
EP2007822B1 (de) 2010-07-21
WO2007116031A1 (en) 2007-10-18
US7915356B2 (en) 2011-03-29

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